Method of shaping



Apljil 13, 1937. A. s LEW|S 2,077,118

METHODA oF sHAPING Filed oct. 14, 19:55

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Patented Apr. 13, 1937 STATE-s PATENT OFFICE 2,077,118 Y METHOD oF-sHAPING 4 y Albert Sidney Lewis, Atlanta, Gra.

Application October 14, 1935, Serial No. 44,942'

3 Claims.

5 lar-type ofv cutter required for each design or cut to be made in fiber board and the like. y One of the principal objects of this invention is the provision of a cutter insert for each design to be cut in fiber board, the dimensions ofthe opening formed inftlie insert being governed'by thedepth of the particular cut ordesignjand theperimeter of said opening constituting a supporting edge tting closely the edges of the cutting element or blades to prevent ravelling o r spalling 'of' the edges of the bervboard surrounding the cut or intaglio design as the latter is beine `formed. v

An important object of this invention is the provision of 'a cutter insert for the table of rotary 2U sawing, cutting and routing machines for efecting cuts or intaglio designs, more especially in fiber board made from compressed vegetable or mineral fibers, each of said inserts being formed in'blank, inserted in the machine table and then Fig. 6 is a fragmentary top plan view of a modied form of insert.

Fig. '7 is a fragmentary detailed view of different types of cutter blades.

Fiber boards are made from compressed vege- 5 table or mineral fibers and are customarily'used in the building industry for vpurposes of decoration, sound absorption, insulation, and the like, and owing to the fact that such boards have short fibers, no grain, and the material being of comparatively low density, it has heretofore been impossible to cut intaglio designs in them by the use of the ordinary cutterV insert without the edges of the cut or designs becoming torn away, ravelled or spalled during the cutting process', and, therefore, it Was to overcome the deficiencies of the cutter inserts and results of the machines heretofore in use, by utilizing each cutter adapted'to form a particular design intaglio in a fiber board, to rst form the opening in a blank d insert constituting a portion of the Work supporting table of the machine, so that the edge of the perimeter of the opening Would constitute a Work supporting edge closely fitting said cutter, lthe ,35 having'the cutter initially operate to form the size of the opening depending upon the depth of 25 opening therein,so that the edge of the perimeter the design to be cut, and then to successively cut of said opening will conform exactly to the conthe design in the board supported on said table tour of Vsaid rotary cutter and constitute a supand insert When moved into engagement thereporting' edge closely tting said cutter, the di- With, that I designed the insert andfmethod of mension of the opening being controlled by the making same forming the subject matter of this 30 depth of the design or cut to be made, the coninvention. tinued operation of said cutter then effecting In the illustrated embodiment characterizing the predetermined cut or intaglio design withthis invention there is sho-Wn al sawing or cutting out tearing away, ravelling or spalling the edges machine work supporting table A, a .cutter v inof the design. ser-t B constituting a section of said table, a ro- 35 With these and other objects in View, which tarycutter element C, and the Work being Op- Will become apparent as the description proceeds, erated on D. Y theinvention resides in the construction, com- The table i-is formed with a cut out portion bination and arrangement of parts, hereinafter l 'and SlllrOun- DE Said POIOII iS 2' Countersunk .i0 more fully described and claimed, and illustrated portion 2 adapted t0 form a lSeat for and Support- 40 inthe accompanying drawing, inwhich like charing lthe 011151261 insert B (Fig. 5) with its upper acters 'of reference indicate like parts throughsurface flush with and constituting a continuaout the several gures, of which: tion of the Work supporting surface of the table Fig. `1 is a fragmentary side elevation of a and ,is formed centrally thereof With an Opening rotary cutter and Vmovable table in inoperative 3 thrOllgh which iS adapted t0 extend the'IOtary 45 position Vshowing the blank insert in position.

Fig. 2 is a similar view of the table in operative Work supporting position showing the cutter extending through the opening formed by it in the insert and in process of cutting the design.

Fig. 3 is a fragmentary top plan view of Fig. 2 with the Work removed.

Fig. 4 is a cross section view of Fig. 2.

Fig. 5 is a similar view to Fig. 4 showing the cutter 'element Cginthe present instance, formed with a plurality of circumferentially 'disposed blades 4.

' The table A is vertically adjustable with respect to the saw or cutter element C so as to ef- 5 scribed including the insert B, as shown in Fig.

5 and designated the prior art, being of conventional design, a detailed description of the means for raising and lowering the table is deemed unnecessary and hence is not shown on the drawing.

While machines constructed and operated as above described have been more orless efficiently used in the wood working industry, they have been found deficient in cutting or forming cuts or designs intaglio in fiber board, since in connection with the latter it has been found impossible to eifect the design without tearing away, ravelling or spalling the edges as illustrated at (a) in Fig. 5 and which deiiciency has in many instances been more pronounced by the use of certain types of cutters, the space (b) of necessity having to be of sufficient dimension to accommodate all of the types of cutters normally used, and,

therefore, providing no supporting edge directlyA adjacent to and closely fitting completely around the edges of the cutters. It has been found necessary in working ber board, to effect smooth unravelled edges of the cuts or intaglio designs, that the edge of the perimeter of the opening in the insert exactly fit the edges of the cutters, so as to form a support for the edges of the cuts or designs being formed in the fiber board.

In order to prevent ravelling or spalling of the edges of the design during the process of forming in materials such as fiber board, a blank insert B, as shown in Fig. l, is placed in the table A, the cutter blades 4 of the type required to pro-k duce the desired design in materials D are mounted on cutter element C which is caused to rotate. V,The table A is then moved to bring the blank insert B into engagementv with the rotating cutter and downwardly until the cutter has passed through and projected above the surface of insert B a distance equal to the depth of the cut 5 to be made in work D, where it remains during the cutting operation. The workD is then directed over the surface of said table in engagement with the rotary cutter during the design forming process. Therefore, it will be apparent that in forming the insert and the design as above described the perimeter or edge 6 of opening 3 exactly conforming to the contour of the cutters will correspond exactly to the contour of and support the edge of the design El, as shown in Fig.

4, thereby eliminating the space (b) and conse` quent ravelled edge (a) heretofore prevalent, as shown in Fig. 5.

It will thus be seen that a new insert is produced for each type of work with its opening conforming exactly to the contour of the design, and in accordance with the depth of the design, the insert and design being formed in one ccntinuous operation.

Fig. 7 shows different types of cutters or cutter blades 4a and 4b, and Fig. 6 illustrates another form of insert opening 3a, wherein the type of blade ia is adapted to cut the design in work D.

The manner of forming an insert for each type of design and the operation of successively effecting the design, with the attendant advantages, would seem to be suiciently clear from the above description as to warrant further explanation unnecessary.

From the above it will be apparent that have designed a method and insert, adapted to effect cutting of intaglio designs in ber board at a minimum expenditure of time, labor, and production cost, and eicient for the purposes intended.

Although in practice I have found that the forniof my invention illustrated in the accompanying drawing and referred to in the above descrip? tion as the preferred embodiment 1s the most efl cient and practical; yet realizing the conditions concurrent with the adoption of my invention will necessarily vary, I desire to emphasize that various minor changes in details of construction, proportion and arrangement of parts, may be re- 'v sorted to within the scope of the appended claims without departing from or sacrificing any of the" principles of this invention.

Having thus described my invention, what I dei sire protected by Letters Patent is as set forth in the following claims:

1. A method of producing intaglio designs in ber board, consisting in placing a blank insert in the table of a rotary cutting machine, moving. said table in engagement with said cutter to forni an opening in the insert exactly fitting the con,-` tour of that portion of the cutter projecting above the surface of the insert a distance equal to the depth of the design to be made, the ends of said opening conforming to the design forming edges of the cuttenand then subjecting the ber board carried by said table to the cutting action of said,l cutter to produce in said board the predetermined.V design. l .L5

2. A method of producing a design in fibeii board, consisting in placing a blank insert in thfe table of a machine having a rotary cutter, mov v ing said table in engagement with said cutter to form an opening in the insert, the ends of the perimeter of the opening conforming exactly t9, the contour of the cutting edge of the cutter, and then subjecting the fiber board carried by said' table to the cutting action of said cutter to effect' therein the predetermined design, the edges 0I the design being progressively supported by the perimeter edge of said insert opening during cutting operation, whereby ravelling of the edges of the design is prevented.

3. A method of producing a predetermined design in fiber board and the like, and cutter insert corresponding to said design, consisting in plac-` ing a blank insert in the table of a machine having a rotary cutter adapted to effect said predetermined design, moving said table with the insert in engagement with the cutter until the latterv has formed an opening in the insert and is projected above the surface thereof a distance equal to the depth of the predetermined design, then, directing over the surface of the table and insert the work in engagement with the cutter, whereby. portions of the edges of the perimeter of the insert opening are coincident with the edges of the design being formed and which are progressivelyr supported thereby during the design forming operation to effect clean cut unbroken edges of the design. ALBERT SIDNEY LEWIS. 

